Cast concrete paver block

ABSTRACT

Precast concrete paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, the tapered joint projection on each block enters the joint recess on the other block. The taper on the projections move the blocks to align the block surfaces. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

TECHNICAL FIELD

The invention relates to precast concrete products and more particularlyto a precast concrete paver block.

BACKGROUND OF THE INVENTION

Precast concrete paver blocks are used for many applications, such aspatios, driveways, sidewalks and courtyards. In the past, concrete paverblocks have generally been relative small, frequently from about thesize of a brick up to about 2 feet square (about 61 cm square). In someapplications, thin, decorative pavers are used as overlays on concretefoundations. Large pavers have not been available. One problem withlarger paver blocks is to maintain a flat surface where the blocks abut.It is difficult to provide a flat foundation for the blocks and toprevent shifting of the blocks with ground movement, for example, due tofrost or heavy rainfall.

BRIEF SUMMARY OF THE INVENTION

The invention is directed to large precast concrete paver blocks of atype suitable for constructing driveways, sidewalks, patios, courtyards,boat ramps, and the like. Optionally, the exposed surfaces of the blocksare textured and, optionally, colored, to simulate natural stone. Thepaver blocks are provided with interlocking edge joints so that abuttingedges of adjacent paver blocks align when the blocks are installed andare maintained in alignment. At each edge joint, each block includes atapered projection and a recess. When edges of two blocks are moved toabut each other, each tapered projection on each block enters a recesson the other block. The taper on the projections move the blocks intoalignment. Preferably, there are at least two edge joints on each blockedge which will abut another block edge. The edges of the blocks areangled or relieved below the joints to ensure a tight fit at the top ofthe paver blocks.

Accordingly, it is an object of the invention to provide cast concretepaver blocks with edges which interlock for initially aligning and formaintaining alignment of abutting block edges.

Other objects and advantages of the invention will become apparent fromthe following detailed description of the invention and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view showing an exemplary layout fora driveway, a sidewalk, steps and a patio constructed with cast concretepaver blocks according to the invention;

FIG. 2 is a top plan view of a rectangular paver block according to theinvention;

FIG. 3 is a top plan view of a corner payer block according to theinvention;

FIG. 4 is a top plan view of a square paver block according to theinvention;

FIG. 5 is a top plan view of a triangular paver block according to theinvention;

FIG. 6 is an enlarged fragmentary cross sectional view showing detailsof the connection between abutting edges of two paver blocks accordingto the invention;

FIG. 7 is a fragmentary side view of abutting edges of two paver blockswhich have a slight angle between the blocks; and

FIG. 8 is a fragmentary cross sectional view showing details of onejoint on one of the paver blocks.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an exemplary layout 10 is shown for a residentialapplication including a driveway 11, a sidewalk 12, steps 13 and a patio14 made from different types of cast paver blocks. The illustratedlayout 10 is formed from four different shaped blocks, consisting ofrectangular paver blocks 15, corner paver blocks 16, square paver blocks17 and triangular paver blocks 18. Although the four illustrated blockshapes will work for most applications, it will be appreciated thatother block shapes also may be made to meet specific applicationrequirements.

The blocks 15-18 are cast from concrete and, preferably, are reinforcedwith steel mesh or with rebar rods to provide the strength required forthe application. For example, greater reinforcement will be needed forpaver blocks used in a driveway 11 which must support the weight ofheavy vehicles, than for paver blocks used in a patio portions of asidewalk 12 which do not cross a driveway. The blocks 15-18 are cast toa desired thickness, such as 4 inches (10.2 cm). In order to provide apleasing appearance, the exposed top surfaces and any exposed edges ofthe blocks 15-18 may be textured, for example, to simulate naturalstone. The block surfaces also may be stained or otherwise colored tomore closely simulate stone using techniques which are well known in theart or to provide a desired appearance.

According to the invention, the sides of the blocks which abut the sidesof other blocks are provided with one or more joints 19 which engagecomplimentary joints on the other blocks. The joints 19 are spaced oneach block side for engaging the complimentary joint 19 on an abuttingblock side. FIG. 2 shows the rectangular block 15 as having two shortsides 20 and 21, each having two joints 19, and as having two long sides22 and 23, each having three joints 19. The rectangular block 15 mayhave, for example, a width of 4 feet (122 cm) and a length of 6 feet(183 cm).

FIG. 3 shows details of the corner block 16. The block 16 issubstantially trapezoidal in shape having a side 24 which is either 4feet (122 cm) or 6 feet (183 cm) long, two angled sides 25 and 26 whichare 4 feet (122 cm) long and, for example, form an angle of 30° to eachother, and a side 27 which is shorter than the side 24. In order to keepthe width of the block at 4 feet or the width of the rectangular blocks15, ends 28 of the side 24 are slightly angled. By arranging the sides25 and 26 at an angle of 30°, three corner blocks 16 can be used to forma 90° bend. If the sides 25 and 26 were angled at 45°, two blocks 16would be used to form a 90° bend. The block 16 is intended to have thesides 25 and 26 abut sides of other blocks 15-18. Thus, the sides 25 and26 are each provided with two joints 19. The center portion of the side24 (without the ends 28) may be of the same length as the side 27, forexample, either 4 feet (122 cm) or 6 feet (183 cm). This will allowabutting a block to the center portion of the side 24.

FIG. 4 shows the square block 17, which has-four sides 29-32, each ofwhich is 4 feet (122 cm) long. Each side 29-32 has two joints 19.

FIG. 5 shows the triangular block 18, which has two adjacent 4 feet (122cm) long sides 33 and 34 which form a 90° angle and a long side 35. Eachof the sides 33 and 34 has two joints 19 for engaging joints on theother blocks.

FIGS. 6-8 show details of a construction for the joints 19. Each joint19 extends along an edge 38 of the block parallel to a top surface 39 ofthe block. Each joint 19 consists of a projecting rib 40 and of a groove41 sized and shaped to receive a projecting rib 40 from a joint 19 on anabutting block. Preferably, the rib 40 is triangular or wedge shaped incross section with sides 42 and ends 43 which taper to an apex 44. Thus,the sides 42 are trapezoidal shaped and the ends 43 are triangularshaped. The groove 41 has complementary tapered sides and ends which aresized to receive the rib 40. Consequently, when two joints 19 are movedinto position where the adjacent sides 38 abut, as shown in FIG. 6, thetop surfaces 39 of the adjacent blocks are moved into alignment when therib 40 is moved into the groove 41. Tapering the ribs 40 in twodirections facilitates alignment of the blocks when they are positionedto form a desired layout. In the drawings, the rib 40 and the groove 41for each joint 19 are shown as being aligned and adjacent each other. Itwill be appreciated that the rig 40 and the groove 41 may be spaced fromeach other, so long as they have the same spacing from the top surface39.

A lower portion 45 of the edge 38 on each block may be angled slightlyinwardly from the joint 19 to a bottom 46 of the block to form an anglebetween the lower portion 45 and the bottom 46 greater than 90°.Optionally, a chamfer may be provided between the lower portion 45 andthe bottom 46 to eliminate sharp edges which may be subject to impactdamage when installing the paver block. The angled lower portion 45serves two functions. First, it allows a relief area for any dirt orother foundation material which may be trapped between the abuttingedges. Second, it allows two adjacent blocks to be slightly angledrelative to each other when the ground on which the blocks are placed isnot level, while maintaining a tighter fit at the top of the paverblock.

The joints 19 are formed to have the same configuration on each side ofthe block which will abut a side of another block. Thus, when looking atan elevational view of any block side having a joint 19, the rib 40 willbe on the left side of the joint 19 and the recess 41 will be to theright of the rib 40. As a consequence, when any two sides are moved intoan abutting arrangement, the two joints are complementary and each rib40 will align with a recess 41. Alternately, all of the joints 19 can bemade with the ribs 40 on the right and the recesses 41 on the left.

The joints 19 may be omitted from edges of the cast paver blocks whichwill not abut an adjacent paver block, especially any of these sideswhich may be visible after the blocks are installed. These edges may betextured with a pattern and colored similar to the exposed top surfaceof the block.

It will be appreciated that various modifications and changes may bemade to the above described preferred embodiment of a cast concretepaver block without departing from the scope of the following claims.Although a preferred construction for the joints 19 has been described,it will be appreciated that other configurations also may be used toachieve the same results. For example, the ribs 40 can be replaced withround or oval knobs and the recesses 41 can be configured to receive theknobs. Also, the number of joints 19 on each side of the paver blocksmay be changed to meet the needs for any particular application.

The block dimensions provided herein are intended to be exemplary. Itwill be appreciated that the block dimensions can be modified to meetlocal building codes and conventional sized in the community in whichthe blocks are used. However, the invention is particularly useful forpaver blocks having a minimum dimension of at least 3 feet (91 cm) forproviding larger hard surfaces.

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 10. (canceled) 11.A cast concrete paver block having a top surface, a bottom, and six sideedges, first and second of said side edges extending parallel to eachother, third and fourth of said side edges joining opposite ends of saidfirst side edge and each extending at angles greater than 90° to saidfirst side edge whereby extensions of said third and fourth side edgesconverge, and fifth and sixth of said side edges connecting betweenopposite ends of said second side edge and ends of said third and forthside edges.
 12. A cast concrete paver block, as set forth in claim 11,and wherein said first and second side edges are of the same length andat least as long as said third and forth side edges.
 13. A cast concretepaver block, as set forth in claim 13, and wherein said first side isshorter than said second side.
 14. A cast concrete paver block, as setforth in claim 11, and wherein said first and second side edges arespaced apart by a predetermined distance, and wherein the third andfourth side edges each have a length substantially equal to saidpredetermined distance.
 15. A cast concrete corner paver block forforming a bend in a sidewalk formed from a series of rectangularconcrete paver blocks having a predetermined width, said corner paverblock having a top surface, a bottom, and six side edges, first andsecond of said side edges extending parallel to each other, third andfourth of said side edges joining opposite ends of said first side edgeand each extending at angles greater than 90° to said first side edge,fifth and sixth of said side edges connecting between opposite ends ofsaid second side edge and ends of said third and forth side edges, andwherein said third and fourth side edges each have a lengthsubstantially equal to said predetermined width.
 16. A cast concretecorner paver block, as set forth in claim 15, and wherein extensions ofsaid third and forth side edges converge.
 17. A cast concrete cornerpaver block, as set forth in claim 16, and wherein said third and forthside edges converge at an angle of 30°, whereby three corner paverblocks positioned with third and fourth edges of adjacent blocksabutting form a 90° bend.
 18. A cast concrete corner paver block, as setforth in claim 16, and wherein said third and forth side edges convergeat an angle of 45°, whereby two corner paver blocks positioned withthird and fourth edges of adjacent blocks abutting form a 90° bend.